Commercialization Potential of Carbon Capture … Library/Events/2017/crosscutting... ·...
Transcript of Commercialization Potential of Carbon Capture … Library/Events/2017/crosscutting... ·...
© 2017 Process Systems Enterprise Limited
Adekola Lawal
Commercialization Potential of Carbon Capture Simulation Initiative (CCSI) Tools
Award Number FE0026307
NETL Crosscutting Research Portfolio ReviewPittsburgh, PA22nd March 2017
© 2017 Process Systems Enterprise Limited
Outline
Making the case for advanced process modelling
PSE background
CCSI Toolset Commercialization Project
Background
Project Overview
Screening and assessments
Case studies: Improving commercial potential
Summary
© 2017 Process Systems Enterprise Limited
What does that mean?First-principles
models
Validated against data
(where appropriate)
Rigorous physical
property calculations
TASK language for
operating policyRigorous
optimisation
… based on accurate predictive models
ADVANCED PROCESS MODELLING
A combination of high-fidelity modelling, advanced optimisation and system analysis techniques within an equation-oriented framework
Decisions, decisions …
Major equipment
design
Catalyst
choices
Operating conditions
Scale up
Operating
policy
Flowsheet
configuration
Equipment
configuration
Key PSE advantagesresulting from equation-oriented approach
Reduce uncertainty
Better, faster, safer decisions
Explore decision space rapidly
Create competitive advantage
© 2017 Process Systems Enterprise Limited
PSE BACKGROUND: FROM RESEARCH TO INDUSTRY
Chemicals & Petrochemicals
Oil & Gas
Formulated
Products
Established sectors
Energy & Environment
Strategic initiatives
© 2017 Process Systems Enterprise Limited
CCS Advanced Process Modelling Tool-kit Project
$5.5m project
3 year development (2011-2014)
Tool tested using several case studies provided by consortium members
Created a commercially available product
built on PSE’s gPROMS platform
high-fidelity “end-to-end” CCS modelling tool
Modelling technology & expertise
Management
© 2017 Process Systems Enterprise Limited
gCCS v1.1 scope
Process models Power generation
Conventional: PC, NGCC
Non-conventional:oxy-fuelled, IGCC
Solvent-based CO2 capture
CO2 compression & liquefaction
CO2 transportation
CO2 injection in sub-sea storage
CO2 Enhanced Oil Recovery
Materials models cubic EoS (PR 78)
flue gas in power plant
Corresponding States Model
water/steam streams
SAFT-VR SW/ SAFT- Mie
solvent-containing streams in CO2 capture
SAFT- Mie
near-pure post-capture CO2
streams
Open architecture allows incorporation of 3rd party models
Costing models Equipment CapEx & OpeX
© 2017 Process Systems Enterprise Limited
Governor valve
Feed Water Heaters
Deaerator Condenser
Generator
Coal
Air
Boiler
Turbine sections
Flue gas treatment
gCCS Power Plant library – conventional power generation
Supercritical pulverized coal power plant
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gCCS Power Plant library – conventional power generation
Combined Cycle Gas Turbine power plant
Gas Turbine
Condenser
Generator
Steam turbines
Steam drums
Economisers, superheaters, evaporators
Input flexibility:Total power output or natural gas flowrate specified
Air
Natural Gas
Steam to Capture Plant
Condensate return
Stack
© 2017 Process Systems Enterprise Limited
gCCS Power Plant library – advanced power generation
Oxyfuel system
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CO2 inlet
Absorber
Direct Contact Cooler (DCC)
Buffer Tank
Stripper
Reboiler
CondenserCO2 capture
rate controlerSolvent /water make-
up controlers
gCCS CO2 Capture library – Solvent-based CO2 capture
“Standard” Amine plant
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gCCS CO2 Capture library – Solvent-based CO2 capture
Physical absorption (SelexolTM process)
H2S Absorber
Stripper
CO2
Absorber
Flash Drum
Reboiler
Condenser
SelexolTM
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gCCS CO2 Capture library – Solvent-based CO2 capture
Activated amine capture plant
Absorber
Stripper #1
Stripper #2
Flash Drum
Reboiler
Condenser
aMDEA
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gCCS CO2 Capture library – Solvent-based CO2 capture
Advanced PCC configurations
Solvent intercooling
Alternative solvent-based capture plant
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Solvent intercooling
Vapour recompression
gCCS CO2 Capture library – Solvent-based CO2 capture
Advanced PCC configurations
Alternative solvent-based capture plant
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gCCS CO2 Compression & Liquefaction library
CO2 compression plant
Fixed speed electric drive
Variable speed electric drive
Dehydration unit
Cooler KO drum
Compression section
(Frame #1: 4 ; Frame #22)
Surge valve
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PipelinesSchedule 40, 18’’
Emergency shutdown valves
(ESD)Gate valve
Vertical riser from sea bed
CO2 flowmeter
gCCS CO2 Transmission & Injection library
CO2 transmission pipelines
20km
16
0m
200km
-20
0m
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Wells7’’, 2km
Distribution header
Choke valves
Reservoir~250 bar
Wellhead connections
20m above water, 70m submerged
gCCS CO2 Transmission & Injection library
CO2 injection & storage in reservoir
© 2017 Process Systems Enterprise Limited
gCCS CO2 Enhanced Oil Recovery library
CO2 EOR
Surface facilities
Sub-surface facilities
Fresh CO2 supply
Produced waterProduced crude oil
Produced sales gas
Water injected
Gas treating unit
Membrane
Cooler
CO2 Pump
CO2 compressors
Three phase
separator
Reservoir
Production
well CO2
injection well
Water
injection well
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Steady-state analysis
Power generation
100%0%
75%0%
50%0%
100%90%
100%50%
75%90%
50%90%
100%90%
Summer
100%90%
Winter
: coal milling + power plant auxiliaries
: coal milling + power plant auxiliaries+ CO2 compression
: capture plant steam
PowerCapture
© 2017 Process Systems Enterprise Limited
3 4 5 6 7 8 9 1036
37
38
39
40
41
Net
Eff
icie
ncy (
%)
3 4 5 6 7 8 9 1080
100
120
Reboile
r ste
am
dem
and (
kg/s
)(b) Power plant net efficiency vs reboiler steam demand
Time (hours)
3 4 5 6 7 8 9 10600
700
800
Mass f
low
rate
(kg/s
)
3 4 5 6 7 8 9 10400
500
600
700
800
Net
Pow
er
(MW
e)
(a) Flue gas mass flowrate
Operational analysis
Power/CO2 capture two-way coupling
Flue gas flowrate
Power plant net efficiencyvs. reboiler steam demand
© 2017 Process Systems Enterprise Limited
0.0
0.2
0.4
0.6
0.8
1.0
0 10 20 30 40
Natu
ral gas R
evenue [
m$]
Time [years]
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200
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600
800
Cru
de o
il revenue [m
$]
Natural gas Revenue (left) Crude oil revenue (right)
0
10
20
30
40
0 10 20 30 40
Mass f
low
[kg/s
]
Time [years]
Injected CO2 mass flow
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10
20
30
40
0 10 20 30 40
Mass f
low
[kg/s
]
Time [years]
Injected CO2 mass flow
0
10
20
30
40
0 10 20 30 40
CO
2 f
low
[kg
/s]
Time [years]
Purchased CO2 Recycled CO2
0.0
0.2
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0.6
0.8
1.0
0 10 20 30 40
Natu
ral gas R
evenue [
m$]
Time [years]
0
200
400
600
800
Cru
de o
il revenue [m
$]
Natural gas Revenue (left) Crude oil revenue (right)
0
10
20
30
40
0 10 20 30 40
CO
2 f
low
[kg
/s]
Time [years]
Purchased CO2 Recycled CO2
Operational analysis – sub-systems
Analysis of CO2 EOR with supply constraints
0
10
20
30
40
0 2 4 6 8 10 12 14 16 18 20 22
CO
2 f
low
[kg/s
]
Time [years]
Purchased CO2 Recycled CO2
0.0
0.2
0.4
0.6
0.8
1.0
1.2
0 10 20 30 40
Natu
ral gas R
evenue [
m$]
Time [years]
0
100
200
300
400
Cru
de o
il revenue [m
$]
Natural gas Revenue (left) Crude oil revenue (right)
Unconstrained supply
Constrained supply
0
10
20
30
40
0 2 4 6 8 10 12 14 16 18 20 22
CO
2 f
low
[kg/s
]
Time [years]
Purchased CO2 Recycled CO2
0.0
0.2
0.4
0.6
0.8
1.0
1.2
0 10 20 30 40
Natu
ral gas R
evenue [
m$]
Time [years]
0
100
200
300
400
Cru
de o
il revenue [m
$]
Natural gas Revenue (left) Crude oil revenue (right)
Phase 3
Phase 1
and 2
Phase 3
© 2017 Process Systems Enterprise Limited
gCCS applications
Optimizing start-up and shutdown procedures of gas treating plants[Shell]
CCS chain and network studies [Energy Technologies Institute and Shell]
Techno-economic study of Industrial Carbon Capture and storage [DECC and Element Energy]
Development of novel technology for Low Emission Intensity Lime and Cement (LEILAC, Horizon 2020)
© 2017 Process Systems Enterprise Limited
The Carbon Capture Simulation Initiative (CCSI) commercialization project
Background
© 2017 Process Systems Enterprise Limited
U.S. Carbon Capture Simulation Initiative (CCSI)
David Miller (2016), CCSI2 Overview and Key Capabilities, NETL CO2 Capture Technology Meeting
© 2017 Process Systems Enterprise Limited
Carbon Capture Simulation Initiative (CCSI)
Miller D C et al., (2015). Multi-scale modelling of carbon capture systems, IEAGHG, PCCC3
© 2017 Process Systems Enterprise Limited
U.S. Carbon Capture Simulation Initiative (CCSI)
Background
Miller D C et al., (2015). Multi-scale modelling of carbon capture systems, IEAGHG, PCCC3
© 2017 Process Systems Enterprise Limited
CCSI CRADA – GE / WVU / LANL
Teresa Grocela-Rocha (2016). Industrial Success Story: DOE-GE CRADA for CCSI Modeling, NETL CO2 Capture Technology Meeting
© 2017 Process Systems Enterprise Limited
Advanced Process Control (APC) Framework
Priyadarshi Mahapatra, Stephen E. Zitney (2016) APC Framework
© 2017 Process Systems Enterprise Limited
The Carbon Capture Simulation Initiative (CCSI) commercialization project
Project overview
© 2017 Process Systems Enterprise Limited
Project partners
Prof Debangsu BhattacharyyaCo-Principal
Task leader Process Modelling
Prof David MebaneCo-Principal
Task leader Sorbentfit/SolventFit
…and team
Prof Nick SahinidisCo-Principal
Task leader ALAMO/FOQUS
US Team
UK Team
Principal Investigator(Technical)
Co-Principal Investigator(Commercial)
Principal AE
Project Manager
AE - ALAMO AE - SorbentFit
Consultant
Researcher student• Anca Ostace
Researcher students• Keenan Kocan• Alejandro Mejia
Researcher fellow• Dr Mustafa Kilinc
© 2017 Process Systems Enterprise Limited
Project objectives
Identify opportunities for commercialising components of the CCSI toolkit within the gPROMS platform
Assessment and ranking of tools according to commercial and technical criteria
Develop and demonstrate a clear technical delivery path towards achieving these opportunities
Devise implementation plans and build team for Phase 2
© 2017 Process Systems Enterprise Limited
The Carbon Capture Simulation Initiative (CCSI) commercialization project
Screening and assessments
© 2017 Process Systems Enterprise Limited
Carbon Capture Simulation Initiative (CCSI)
Fast track tools and screened tools
Process ModelsFOQUS Turbine and SimSinter
ALAMO SolventFit/SorbentFit
Fast track tools
Screened tools
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CMU (ALAMO)
Optimization-based machine learning methodology
Capable of transforming data and complex models to algebraic models
© 2017 Process Systems Enterprise Limited
SWOT ANALYSIS
Featured Opportunities
• Process Models: High fidelity gas-solid models could be extended to other process applications
• ALAMO: Could be used to speed up and automate UQ investigations
• FOQUS TURBINE: Parallelized simulations on cloud
• SorbentFit: Bayesian estimation provides unique capabilities
© 2017 Process Systems Enterprise Limited
Feedback from potential customers
“Improve user friendliness”
“Need to demonstration value”
“Limited scope”
“Why change?”
“Simulation time”
“cutting-edge technology”
“certain tools can be used outside CCS”
“ability to use with commercial simulators is a plus”
“Complex work flow”
“Concerned about long-term support”
© 2017 Process Systems Enterprise Limited
The Carbon Capture Simulation Initiative (CCSI) commercialization project
Case studies: Improving commercial potential
© 2017 Process Systems Enterprise Limited
Extending model scope
gCCS Power plant gCCS CO2 Compression
CCSI BFB and MB models
H2 purification model validationFixed bed model
developed
© 2017 Process Systems Enterprise Limited
Proposal for improving workflows and usability
Run ALAMO within gPROMS
© 2017 Process Systems Enterprise Limited
Summary
PSE has assessed the CCSI toolset for commercialization within its advanced modelling platform, gPROMS
The CCSI toolset represents cutting-edge research in the development of CCS
PSE has identified and proposed development areas for the commercialization of the tools especially with regards usability and demonstration of additional value
PSE will continue to support the CCSI2 project
© 2017 Process Systems Enterprise Limited
Acknowledgements
This study was performed as part of DOE Award No: FE0026307 with Omer R. Bakshi as Project Manager
NETL: David Miller, Susan Sprake, Ashley Reichl, Steven Seachman, Jason Hissam
Entire CCSI team, John Shinn and the entire Industry Advisory Board
Lawrence Berkeley National Laboratory: Deb Agarwal and Josh Boverhoff
The entire project team
E0026307